CVT Forward Clutch Reassembly

CVT Forward Clutch Reassembly

Special Tools Required

- Clutch Spring Compressor Set 07LAE-PX40000
- Clutch Compressor Attachment 07ZAE-PRP0100

1. Inspect the clutch piston (A) and the clutch piston check valve (B). If the clutch check valve is loose or damaged, replace the clutch piston.





2. Check the spring retainer (C) for wear and damage.

3. Inspect the clutch discs (D), the clutch plates (E), and the clutch end-plate (F) for wear, damage, and discoloration.

- If the clutch discs are worn or damaged, replace the discs as a set.
- If the clutch plates are worn, damaged, or discolored, replace the plates as a set.
- If the clutch end-plate is worn, damaged, or discolored, inspect the clearance between the end-plate and the top disc, then replace the clutch end-plate.

4. Soak the clutch discs thoroughly in CVTF for at least 30 minutes.

5. Install new O-rings (A) on the clutch piston (B).






6. Install the piston (A) in the clutch drum (B). Apply pressure and rotate to ensure proper seating. Lubricate the piston O-ring with CVTF before installing. Do not pinch the O-ring by installing the piston with excessive force.






7. Install the return spring (A) and the spring retainer (B), and position the snap ring (C) on the retainer.






8. Install the clutch spring compressor.






9. Be sure the clutch spring compressor (A) is adjusted to make full contact with the spring retainer (B) on the clutch.






10. Check the placement of the clutch spring compressor. If either end of the clutch spring compressor is set over an area of the spring retainer which is unsupported by the return spring, the spring retainer may be damaged.






11. Compress the return spring.






12. Install the snap ring (A).





13. Remove the clutch spring compressor.

14. Install the wave spring.






15. Starting with the clutch plate, alternately install the clutch plates and the discs. Install the clutch end-plate (A) with the flat side toward the disc (B).






16. Install the snap ring (A) using a screwdriver (B).






17. Check that the snap ring end gap (A) is 7.9 mm (0.311 in) or more.





18. Check that the clutch piston engages by applying air pressure to the fluid passage, and also check that the piston releases when air pressure is released.

19. Set a dial indicator (A) on the clutch end-plate (B).





20. Zero the dial indicator with the clutch end-plate lifted up to the snap ring (C).

21. Release the clutch end-plate to lower the clutch end-plate, then put the clutch compressor attachment on the end-plate (A).





22. Press the clutch compressor attachment down with 49 N (5 kgf, 11 lbf) using a force gauge or equivalent, and read the dial indicator (B). The dial indicator reads the clearance (C) between the clutch end-plate and the top disc (D). Take measurements in at least three places, and use the average as the actual clearance.






23. If the clearance is out of the service limit, select a new clutch end-plate from the following table.






FORWARD CLUTCH END-PLATE





24. Install a new clutch end-plate, then recheck the clearance. If the thickest clutch end-plate is installed, but the clearance is still over the service limit, replace the clutch discs and the plates.